materials
Article
Numerical Simulation and Experimental Verification of
Residual Stress in the Welded Joints of Weldolet–Branch Pipe
Dissimilar Steels
Chunliang Mai 1 , Xue Hu 1, *, Lixin Zhang 1 , Bao Song 1,2 and Xiongfei Zheng 1






Citation: Mai, C.; Hu, X.; Zhang, L.;
Song, B.; Zheng, X. Numerical
Simulation and Experimental
Verification of Residual Stress in the
Welded Joints of Weldolet–Branch
Pipe Dissimilar Steels. Materials 2022,
15, 1044. https://doi.org/10.3390/
ma15031044
Academic Editor: Francisca
G. Caballero
Received: 16 December 2021
Accepted: 26 January 2022
Published: 28 January 2022
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iations.
Copyright: © 2022 by the authors.
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This article is an open access article
distributed under the terms and
conditions of the Creative Commons
Attribution (CC BY) license (https://
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4.0/).
Materials 2022, 15, 1044. https://doi.org/10.3390/ma15031044
1 College of Mechanical and Electrical Engineering, Shihezi University, Shihezi 832003, China;
maichunliang@stu.shzu.edu.cn (C.M.); zhlx2001329@163.com (L.Z.); songbao@hust.edu.cn (B.S.);
zxf13821795839@163.com (X.Z.)
2 College of Mechanical Science and Engineering, Huazhong University of Science and Technology,
Wuhan 430074, China
* Correspondence: huxue@shzu.edu.cn; Tel.: +86-1889-8533-580
Abstract: It is well known that welding dissimilar metals can play the advantages and characteristics
of those different metals, but it is easy to encounter some problems. In this paper, the thermomechan-
ical behavior of the weldolet–branch dissimilar steel joints in different welding cases is analyzed by
establishing a three-dimensional finite element model, and the predicted thermal cycling and residual
stresses are verified using experimental tools. The results show that the high temperature area and
the heat affected zone on the side of the branch pipe are larger, and there is a large stress gradient at
the fusion line on both sides of the weld. Too high or too low temperature between welding layers
will cause large residual stress, thus, 200 ◦ C is more suitable for the welding of weldolet–branch
joints. The residual stresses of path-1, path-2 and path-3 have similar distributions at 0◦ and 180◦
sections, and the circumferential and axial residual stresses on the inner surface are larger than those
on the outer surface. The residual stress on the inner and outer surfaces of path-3 is smaller than that
of path-1 and path-2 at the 90◦ and 270◦ sections as a whole, and the residual stress at the 90◦ section
reaches the minimum.
Keywords: weldolet; branch pipe; interlayer temperature; welding sequence
1. Introduction
As a new type of reinforcing receiver, the weldolet is widely used in pipeline systems of
chemical plants, thermal power plants and nuclear power plants. The weldolet can directly
replace the traditionally used branch pipe connections, such as reducer tees and reinforced
pipe sections, with higher safety and economy. It is especially used more frequently in high
temperature, high pressure and even ultra-high pressure and subcritical pipelines [1–5]. With
the increasing industrialization all over the world, various new structures and equipment
are emerging in an endless stream, the application of new materials and new processes is
becoming more and more extensive, and the research on various new materials and composite
structures is becoming more and more extensive and in-depth. The single material in traditional
industrial manufacturing can no longer meet the needs of various industries, which forces the
manufacturing industry to develop in the direction of lighter structure, multi-function and
low cost [6,7]. In general, the realization of the interconnection of dissimilar materials can
combine the advantages of these materials and compensate for the defects of different materials
themselves, which, to some extent, effectively meets the production requirements [8–10].
In the traditional manufacturing field, 12Cr1MoV and 15CrMo are both indispensable
engineering materials. Both 12Cr1MoV steel and 15CrMo steel are low-alloy pearlitic heat-
resistant steels, which are widely used in high-temperature and high-pressure steam pipes
and superheater pipes due to their good oxidation resistance, high strength and plasticity,
https://www.mdpi.com/journal/materials
Materials 2022, 15, 1044 2 of 22

simple production process and high lasting strength at higher temperatures [11–13]. In
practical engineering, we often encounter problems with the welding of two types of steel.
Compared to the welding of the same material, welding between dissimilar materials is
much more difficult. The physical properties and chemical composition of the metal itself
limit the welding quality, and the difference in the welding performance of the two metals
will affect the weldability between them to a greater extent [14–17]. Therefore, in order to
achieve a high-efficiency and high-quality connection between 12Cr1MoV and 15CrMo,
it is necessary to choose a reasonable welding method, formulate a reasonable welding
process and ensure the quality and mechanical properties of the weld joint.
Since the advent of the thermal-elastoplastic finite element model, numerical simula-
tion research on welding stress and deformation of the same type of steel and dissimilar
steel has been developed rapidly. The welding finite element modeling process mainly
includes moving heat sources, temperature-related material thermophysical properties,
thermal and mechanical analysis, etc. [18]. The most important component in the finite
element modeling process of dissimilar steel is to give different material performance
parameters to different welded components, and these thermophysical performance pa-
rameters all change with temperature. Trupiano et al. [19] introduced a new equivalent
parametric modeling method for simulating longitudinal multi-pass welds on planar struc-
tures such as slabs and rectangular hollow sections. The proposed Welding Equivalent
Model (WEM) employs single-layer and multi-layer shell, link and beam elements. It helps
detect residual stresses and local deformations typical of multi-pass welds. Lee et al. [20]
predicted the temperature field and residual stress state in welded joints of carbon and
stainless steels based on the finite element method, and the results showed that the weld
residual stresses in dissimilar steel butt welds are different from those in corresponding
similar steel butt welds. Huang et al. [21] used SYSWELD software to carry out numerical
simulation and experimental verification of the temperature field, HAZ microstructure
evolution, residual stress and post-weld deformation of S355JR-316L dissimilar metals.
Sauraw et al. [22] achieved the joining of P91 and P22 steels using a gas tungsten arc
welding (GTAW) process, and measured the microstructural inhomogeneity and element
diffusion across the interface of the welded joint. At the same time, the mechanical proper-
ties of the welded joints under as-welded and post-weld heat treatment conditions were
evaluated on the basis of experiments. Sepe et al. [23] performed finite element simulations
and experimental tests on dissimilar steel T-joints, which were analyzed in detail with re-
spect to the temperature distribution during welding and the deformation at the end of final
cooling. Khamari et al. [24] compared and analyzed the mechanical and microstructural
properties of plates with different thicknesses welded by gas tungsten arc welding (GTAW)
and electrode arc welding (SMAW), and designed a new set of welding parameters for
structural steel welding. Karalis et al. [25] investigated the effect of the thermal uncertainty
encountered during shielded metal arc welding (SMAW) of thin welded plates made of
Ck45 steel on the out-of-plane corner deformation of the welded panels by means of the
finite element method and experimental measurements. Taghipour et al. [26] observed the
microstructure of the pipe–flange welded joint fracture and combined it with the simulation.
The study found that the weld bead area at the root of the welded joint is composed of large
grain structures, and the hardness of the weld root area is low. The reason for the fracture is
unreasonable welding parameters. Xia et al. [27] simulated the multi-layer welding process
of dissimilar welded joints through thermal–mechanical coupling analysis. The results
show that, due to the different material properties, the residual stress in different pipe joints
is asymmetric. Due to the welding sequence and the welding start/stop position, the resid-
ual stress distribution is very different. The change in residual stress on both sides of the
weld centerline is more complicated than that of similar welded joints. Pamnani et al. [28]
used finite element model (FEM) simulation to study the thermodynamics of DMR-249A
steel welds fabricated by shielded metal arc welding (SMAW) and active gas tungsten arc
welding (A-GTAW) processes’ properties; the results of the study demonstrate the applica-
bility of the numerical model to be an effective method for predicting the thermomechanical
Materials 2022, 15, 1044 3 of 22

properties of DMR-249A steel welded joints affected by welding techniques. Li et al. [29]
designed a 5%Cr weld metal for 9Cr/2.25Cr dissimilar weld joints. Studies have shown
that the alloy design of 5%Cr weld metal has a significant effect on reducing the degree
of carbon migration at the joint interface. The interface creep damage and early failure
tendency are greatly reduced. Li et al. [30] showed that the solid-state phase transformation
of P92 steel, the strain-hardening and annealing effects of SUS304 stainless steel and the
difference in thermal expansion coefficients between the different metals have a significant
effect on the formation of longitudinal residual stresses in P92/SUS304 butt welds, and that
X-groove butt welds may be superior to single V-groove butt welds in reducing areas of
high residual tensile stresses. The current research on dissimilar steel welding is mainly
focused on flat joints, T-pipe joints or pipe plate joints, etc. However, there is almost no
research for the more special structure of the weldolet. There are two types of welds in the
complete weldolet welding process. One end of the weldolet is a saddle weld, and the other
end is a circumferential weld. The distance between the two welds is very close. Therefore,
strict control of the welding quality of the circumferential weld between the weldolet and
the branch pipe is also very important for the overall safety of the weldolet. Weldolets
are commonly used in the piping system of thermal power plants, the base material is
mostly 12Cr1MoV, the branch pipe is mostly 15CrMo and the welding characteristics of
the two materials are also relatively rare. At the same time, previous research scholars for
dissimilar steel welded joints focus on the analysis of the interface macroscopic structure
of the joint and the mechanical properties of the joint, or they just study the temperature
and residual stress distribution characteristics of dissimilar steel joints, while the different
welding process parameters, such as the welding sequence and interlayer temperature,
for dissimilar steel joints’ temperature and residual stress distribution are less commonly
researched. Therefore, this paper considers both the interlayer temperature and the weld-
ing sequence to carry out the welding process optimization study of the weldolet–branch
dissimilar steel welded joints.
In this study, the hexahedral mesh model was used to simulate and calculate the
welding process of the weldolet–branch pipe dissimilar steel annular weld and verify the
feasibility of the calculation method by means of experimental analysis. By comparing
and analyzing the arc welding process of 12Cr1MoV heat-resistant steel and 15CrMo heat-
resistant steel under nine welding process parameters, the effect of process parameters on
the thermal cycle and residual stress of dissimilar steel joints was revealed, which is of
great significance for the selection and optimization of the process.

2. Experimental Procedure
The experiment object is weldolet–branch pipe dissimilar steel welding. The size
of the weldolet is DN80 × 16 mm, and the material is 12CrMoV steel. The size of the
branch pipe is DN80 × 6 mm, and the material is 15CrMo steel. The selection of welding
materials for dissimilar steel welded joints uses low matching, so the filler metal matching
with 15CrMo is selected. That is, tungsten inert gas welding (GTAW) using H08CrMoA
(China, Guangzhou)heat resistant steel argon arc welding wire and electrode arc welding
(SMWA) welding using R307 electrode. The sizes of the welded joints, the bevel angles
and the distribution of the weld channels are shown in Figure 1. The weldolet–branch
pipe welding adopts a single-sided V-shaped groove. The weldolet is a machined standard
part with its own bevel, and the bevel angle is 30◦ . The branch pipe is machined and also
has a 30◦ bevel. According to the technical regulations for welding of dissimilar steels in
thermal power plants, the interlayer temperature is selected as 12Cr1MoV with a higher
preheating temperature of the parent material, set at 200 ◦ C, and the interlayer temperature
and preheating temperature of the welding process should be consistent. Before welding,
spot weld the measuring ends of the thermocouple on the outer surface of the weldolet side
and the branch pipe side, respectively, and the distance between the measuring point and
the center line of the weld is 16.5 mm. The other end of the thermocouple is connected to the
input end of the temperature measuring instrument, and the temperature value during the
Materials 2022, 15, 1044  12Cr1MoV 4  o
 
Saddle shoulder

weldolet side and the branch pipe side, respectively, and the distance between the m
Materials 2022, 15, 1044 4 of 22
uring point and the center line of the weld is 16.5 mm. The other end of the thermocou
Weldolet
Weldolet
is connected to the input end of the temperature measuring instrument, and the temp
ture value during the welding process is recorded in real time. Figure 2 shows the se
Saddlein
belly
welding process
Branch is recorded
pipe real time. Figure 2 shows the setup of the weldolet–branch
Branch pipe
of the weldolet–branch pipe welding experiment. 
pipe welding experiment.

 
15CrMo
Figure 1. Two‐dimensional (2D) diagram of the weldolet–branch pipe structure. 
12Cr1MoV
During the welding process, no external constraints are imposed on the components, 
Saddle shoulder
so the components can move freely in different directions. Before welding, the surround‐
ing points of the butt joint of the weldolet and the branch pipe are fixed by spot welding. 
The  rust,  oil  and  other  impurities  near  the  groove  are  cleaned  up  before  welding.  The 
experimental process was a two‐layer, two‐pass weld, and the welding sequence was a 
single‐pass  straight‐through  type  with  GTAW  priming  and  SWAM  filler  capping.  The 
Weldolet Weldolet
shielding gas is pure argon, and the welding parameters of the different welding channels 
are shown in Table 1. The workpiece needs to be preheated before welding, and the pre‐
heating temperature and the interlayer temperature are kept the same. 
Branch pipe Saddle belly Branch pipe
Table 1. Welding methods and parameters. 

Welding  Filling  Welding Wire (bar)  Current  Voltage  Welding  Gas 

Levels 
Method  Material  Diameter/mm  I/A  U/V  Speed mm/s  Flow 
GTAW  1  R30  2.5  80~110  15~20  1   
Figure 1. Two-dimensional (2D) diagram of the weldolet–branch pipe structure. 8 L/min 
SMAW  2  R307  3.2  90~120  20~24  1.3 
Figure 1. Two‐dimensional (2D) diagram of the weldolet–branch pipe structure. 

During the welding process, no external constraints are imposed on the compone
Branch pipe Weldolet Thermocouple
so the components can move freely in different directions. Before welding, the surrou
ing points of the butt joint of the weldolet and the branch pipe are fixed by spot weld
The  rust,  oil  and  other  impurities  near  the  groove  are  cleaned  up  before  welding. 
experimental process was a two‐layer, two‐pass weld, and the welding sequence w
single‐pass  straight‐through  type  with  GTAW  priming  and  SWAM  filler  capping. 
shielding gas is pure argon, and the welding parameters of the different welding chan
Fixture
are shown in Table 1. The workpiece needs to be preheated before welding, and the 
a b
heating temperature and the interlayer temperature are kept the same.   
Figure  2. 
Figure 2. The 
Thewelding 
welding experiment  setup 
experiment of  the 
setup ofweldolet–branch  pipe  (a) pipe
the weldolet–branch before 
(a)welding 
beforeand  (b)  and
welding
after welding. 
Table 1. Welding methods and parameters. 
(b) after welding.

  Welding 
  During the welding Filling  Welding Wire (bar)  Current  Voltage  Welding  G
Levels  process, no external constraints are imposed on the components,
soMethod 
the components can move Material  Diameter/mm 
freely in different I/A welding,
directions. Before U/V  Speed mm/s  Flo
the surrounding
GTAW 
points of the butt1 joint of R30 
the weldolet and2.5 the branch pipe80~110  15~20 
are fixed 1 
by spot welding.
  8 L/
The rust, oil and 2 
SMAW  other impurities
R307  near the 3.2  groove are cleaned up before
90~120  welding. 1.3 
20~24  The
experimental process was a two-layer, two-pass weld, and the welding sequence was a
single-pass straight-through type with GTAW priming and SWAM filler capping. The
shielding gas is pure argon, and the welding parameters of the different welding channels
Branch pipe
are shown in Table 1. The workpiece Weldolet Thermocouple
needs to be preheated before welding, and the
preheating temperature and the interlayer temperature are kept the same.

Table 1. Welding methods and parameters.

Welding Filling Welding Wire (bar) Current Voltage Welding Gas

Levels
Method Material Diameter/mm I/A U/V Speed mm/s Flow
GTAW 1 R30 2.5 80~110 15~20 1 8
SMAW 2 R307 3.2 90~120 20~24 1.3 L/min

Fixture
3. Finite Element Analysis
a The rapid professional welding software, SimufactbWelding 2020, was used to simulate
the welding temperature field and residual stress field of the dissimilar steel welded joints.
Figure  2.  The  welding  experiment  setup  of  the  weldolet–branch  pipe  (a)  before  welding  and
after welding. 

   
Materials 2022, 15, 1044  5  of  22 
 

3. Finite Element Analysis 

Materials 2022, 15, 1044

The rapid professional welding software, Simufact Welding 2020, was used to simu‐ 5 of 22
late the welding temperature field and residual stress field of the dissimilar steel welded 
joints. The algorithm of this software is based on the thermo‐elastic–plastic finite element 
model, which can conveniently prepare input data according to welding conditions, weld‐
The algorithm of this software is based on the thermo-elastic–plastic finite element model,
ing seam arrangement and welding sequence [31,32]. The thermal–mechanical behavior 
which can conveniently prepare input data according to welding conditions, welding
was simulated using the sequential thermodynamic coupling method during the welding 
seam arrangement and welding sequence [31,32]. The thermal–mechanical behavior was
process. The calculation method consists of two steps. The first step is the thermal analy‐
simulated using the sequential thermodynamic coupling method during the welding
sis. In this step, the temperature history of all nodes involved in the finite element model 
process. The calculation method consists of two steps. The first step is the thermal analysis.
is calculated based on the welding conditions and thermal boundary conditions. The sec‐
In this step, the temperature history of all nodes involved in the finite element model is
ond step is the mechanical analysis. In this step, the thermal cycles of all nodes calculated 
calculated based on the welding conditions and thermal boundary conditions. The second
in the first step are used as thermal loads. In the actual welding experiment, the flame gun 
step is the mechanical analysis. In this step, the thermal cycles of all nodes calculated in the
is  used  to  preheat  and  ensure  the  interlayer  temperature.  In  the  numerical  simulation, 
first step are used as thermal loads. In the actual welding experiment, the flame gun is used
preheating is performed by setting the initial temperature of different components, and 
to preheat and ensure the interlayer temperature. In the numerical simulation, preheating
the interlayer temperature is controlled by setting the start–stop time of the welding torch. 
is performed by setting the initial temperature of different components, and the interlayer
temperature is controlled by setting the start–stop time of the welding torch.
3.1. Finite Element Modeling 
3.1. The three‐dimensional finite element model of the weldolet, branch pipe and weld 
Finite Element Modeling
channel distribution is shown in Figure 3, and the weld channel is divided into the prim‐
The three-dimensional finite element model of the weldolet, branch pipe and weld
ing layer and the filling cover layer. The mesh division adopts the professional mesh di‐
channel distribution is shown in Figure 3, and the weld channel is divided into the priming
vision software Hypermesh 2019. The most important part of the meshing is to cut the 
layer and the filling cover layer. The mesh division adopts the professional mesh division
model into fusion zone, heat affected zone and other areas. The 2D meshing is performed 
software Hypermesh 2019. The most important part of the meshing is to cut the model
first, and, finally, the 3D mesh is generated with the mapping command. In order to im‐
into fusion zone, heat affected zone and other areas. The 2D meshing is performed first,
prove the computational efficiency and ensure the accuracy of the numerical simulation, 
and, finally, the 3D mesh is generated with the mapping command. In order to improve the
the mesh of the weld and the nearby area is refined, and the mesh of the area far from the 
computational efficiency and ensure the accuracy of the numerical simulation, the mesh
weld is gradually coarsened. The number of elements in the simulation model is 175,630, 
of the weld and the nearby area is refined, and the mesh of the area far from the weld is
and  the  number 
gradually of  nodes 
coarsened. is  201,330. 
The number Figure  4 in
of elements shows  the  finite  model
the simulation element 
is meshing  of  the 
175,630, and the
weldment. 
number of nodes is 201,330. Figure 4 shows the finite element meshing of the weldment.

Thermocouples

Test points: 0°
9.5 7
3.5

Weld center line

90° Distance from weld center line: mm

0°

90°

270°

Path-4
180°
 
Figure 3. Three-dimensional (3D) model of the weldolet and branch pipe.
Figure 3. Three‐dimensional (3D) model of the weldolet and branch pipe. 

 
Materials 2022, 15, 1044  6  of  22
  Materials 2022, 15, 1044 6 of 22

Element:175630
Nodes:201330
Pass.2
90° Pass.1

90°

UxUy Uz 0 180°

 
Figure 4. Finite element model meshing and boundary condition.
Figure 4. Finite element model meshing and boundary condition. 
3.2. Heat Source Model and Thermal Analysis
3.2. Heat Source Model and Thermal Analysis 
In the welding process, the governing equation of heat transfer is as follows:
In the welding process, the governing equation of heat transfer is as follows: 
     
∂T ∂ ∂T ∂ ∂T ∂ ∂T
ρc 𝜕𝑇= 𝜕 λ 𝜕𝑇 + 𝜕 λ 𝜕𝑇 + 𝜕 λ 𝜕𝑇 + Q (1) (1) 
𝜌𝑐∂t ∂ x 𝜆∂x ∂y 𝜆∂y ∂z 𝜆 ∂z 𝑄 
𝜕 𝜕 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕 𝜕
where c is the specific heat capacity of the material, ρ is the density of the material, T is
where  ｃ  is the specific heat capacity of the material,  𝜌  is the density of the material,  𝑇
the temperature, t is the time, λ is the thermal conductivity of the material and Q is the
is the temperature, 
intensity of the internal 𝑡 heat source. 𝜆  is the thermal conductivity of the material and  𝑄̅  is
is the time, 
the intensity of the internal heat source. 
The heat source model plays a crucial role in thermal and mechanical analysis. In this
study,The heat source model plays a crucial role in thermal and mechanical analysis. In this
the double ellipsoidal heat source model proposed by Goldak et al. [33] was used.
Adjusting the heat source parameters according to the actual molten pool shape ensures
study, the double ellipsoidal heat source model proposed by Goldak et al. [33] was used
the calculation accuracy of welding residual stress. The heat flux density in the first half
Adjusting the heat source parameters according to the actual molten pool shape ensures
and the second half of the heat source model can be described by Equations (2) and (3).
the calculation accuracy of welding residual stress. The heat flux density in the first half
√
and the second half of the heat source model can be described by Equations (2) and (3). 
!
6 3ffQ 3x2 3y2 3z2
q f ( x, y, z) = √ exp − 2 − − (2)
6√3𝑓
abc fπ π𝑄 c3𝑥 b3𝑦 a23𝑧
𝑞 𝑥, 𝑦, 𝑧 𝑒𝑥𝑝
f
  (2) 
√ 𝜋 √𝜋
𝑎𝑏𝑐 𝑐 𝑏 𝑎
3x2 3y2 3z2

6 3 fr Q
qr ( x, y, z) = √ exp − 2 − 2 − 2 (3)
abcr π π cr b a
6√3𝑓 𝑄 3𝑥 3𝑦 3𝑧
𝑞 𝑥, 𝑦,
where Q is the heat source 𝑧
power, a, b, c f and𝑒𝑥𝑝
cr are the𝑐ellipsoidal  
parameters, f f and f r are (3) 
𝑎𝑏𝑐 𝜋√𝜋 𝑏 𝑎
the heat distribution of the front and rear ellipsoids, respectively, and f f + f r = 2. Q = ηUI,
U is the 𝑄 
where  welding
is the heat source power,  𝑏, 𝑐 and
voltage, I is the welding𝑎,current and𝑐 η  are the ellipsoidal parameters, 
is the arc efficient. In this study, η 𝑓   and
was assumed to be 0.7. The double ellipsoidal heat source model is shown in Figure 5.
𝑓   are the heat distribution of the front and rear ellipsoids, respectively, and  𝑓 𝑓 2
𝑄   ηUI, U is the welding voltage, I is the welding current and η is the arc efficient. In this
study,  η  was  assumed  to  be  0.7.  The  double  ellipsoidal  heat  source  model  is  shown  in
Figure 5. 
Materials 2022, 15,
Materials2022, 15, 1044
1044
Materials 2022, 15, 1044  7 7 of 
7 of of
22 22
22 
 

 
Figure
Figure 5.
5. Double
Doubleellipsoid
ellipsoidheat
heatsource
sourcemodel.
model.
Figure 5. Double ellipsoid heat source model. 

In
In the
theprocess
processofofnumerical
numericalsimulation
simulation of of
welding,
welding, the the
thermophysical
thermophysical properties of
properties
In the process of numerical simulation of welding, the thermophysical properties of 
the material
of the parameters
material parameters have a significant
have impact
a significant on the
impact oncalculation results.
the calculation The thermo-
results. The ther-
the material parameters have a significant impact on the calculation results. The thermo‐
dynamic
modynamic properties of 12Cr1MoV
properties of 12Cr1MoV andand
15CrMo
15CrMo change
change with temperature;
with temperature; thetherelevant
relevant
dynamic  properties  of  12Cr1MoV  and  15CrMo  change  with  temperature;  the  relevant 
thermophysical
thermophysical property
propertyparameters
parametersofofthethetwo
twobase
basematerials
materialsusedusedininthe thepaper
paperwerewere
thermophysical  property  parameters  of  the  two  base  materials  used  in  the  paper  were 
obtained through
through JMatPro
JMatProprofessional
professionalsoftware.
software.The Thethermomechanical
thermomechanicalpropertiesproperties ofof
the
the
obtained through JMatPro professional software. The thermomechanical properties of the 
two
two base
base materials
materialsareareshown
shownin inFigure
Figure66and
andTable
Table2.2.TheTheweld
weldfilling
fillingprocess
processusesusesthe
the
two base materials are shown in Figure 6 and Table 2. The weld filling process uses the 
“living and dead element
“living element method”,
method”,where
wherewhen
whenthe theheat
heatsource
sourceisisactivated
activatedininthe thearea ofof
area
“living and dead element method”, where when the heat source is activated in the area of 
the element, thethe heat
heatsource
sourcedoes
doesnot
notreach
reachthe
the area of the weld element in an inactive
area of the weld element in an inactive state.
the element, the heat source does not reach the area of the weld element in an inactive 
state. With the movement
With the movement of theofwelding
the welding
heat heat source,
source, the weld
the weld material
material is filled
is filled intointo the
the weld
state. With the movement of the welding heat source, the weld material is filled into the 
weld in turn.
in turn.
weld in turn. 
70 70
Specific heat：C  10 kJ/（kg·℃） Specific heat：C  10 kJ/（kg·℃）
Conductivity： N/(s·℃） Conductivity： N/(s·℃）
60 60
Density：× 10-3 kg/m3 Density：× 10-3 kg/m3
Material properties of 12Cr1MoV

Material properties of 15CrMo

Thermal expansion coefficient： × 106 /℃ Thermal expansion coefficient： × 106 /℃

50 Young's modulus：E × 10-4 MPa 50 Young's modulus：E × 10-4 MPa
Poisson's ratio： × 10 Poisson's ratio： × 10
40 40

30 30

20 20

10 10

0 0
0 300 600 900 1200 1500 0 300 600 900 1200 1500
Temperature(℃) Temperature(℃)
  (a) (b)  
(a)  (b) 
Figure 6. Temperature-dependent thermodynamic properties of (a) 12Cr1MoV steel and (b)
Figure 6. Temperature-dependent thermodynamic properties of (a) 12Cr1MoV steel and (b) 15CrMo
15CrMo steel.
Figure 6. Temperature‐dependent thermodynamic properties of (a) 12Cr1MoV steel and (b) 
steel.
15CrMo steel. 
Table 2. Mechanical and thermal properties of weld metals.
Table 2. Mechanical and thermal properties of weld metals.
Table 2. Mechanical and thermal properties of weld metals. 
Melting Steel Plate Tensile Yield
Weld Metals Elongation Temperature/°C Impact Energy/J
Point/°C Thickness/mm Strength/Mpa Strength/Mpa
Melting 
Melting Steel Plate   
Steel Plate Tensile 
Tensile Yield  Yield ◦C Impact
Weld Metals
Weld Metals 
12Cr1MoV 1520 °C ◦ C Thickness/mm 
6~60 440~590 ≥245 Elongation
Elongation  Temperature/
Temperature/°C  Impact Energy/J 
Point/
Point/°C  Thickness/mm Strength/Mpa
Strength/Mpa  Strength/Mpa≥19
Strength/Mpa  ≥20 ≥47
Energy/J
15CrMo 1500 °C◦ 6~60 450~590 ≥295 ≥19 ≥20 ≥31
12Cr1MoV 
12Cr1MoV 1520 °C 
1520 C 6~60 6~60 440~590 
440~590 ≥245  ≥245 ≥19  ≥19 ≥20  ≥20 ≥47 
≥47
15CrMo 
15CrMo 1500 ◦ C
1500 °C  6~60 6~60 450~590 
450~590 ≥295  ≥295 ≥19  ≥19 ≥20  ≥20 ≥31 
≥31

 
Materials 2022, 15, 1044 8 of 22

The finite element model of this paper considers the heat loss in welding, and the heat
exchange between the weldment and the environment includes two forms: convection heat
dissipation and radiation heat dissipation. Heat loss is described by Newton’s law (4) and
Stephen–Boltzmann’s law (5).
Qc = h( T − T0 ) (4)
 
Qr = εσ T 4 − T04 (5)

where h is the heat transfer coefficient (20 W m−2 ·K−2 ), T is the surface temperature of the
weldments, T0 is the ambient temperature (25 ◦ C) and ε is the thermal emissivity. Given
0.6, σ is Stefan–Boltzman constant.

3.3. Mechanical Analysis

In the mechanical analysis, the results of the thermal analysis are loaded into the
elastic–plastic analysis as thermal loads, and the total strain of the material in the finite
element model can be described by the following equation:

εtotal = εe + ε p + εth + εtr (6)

where εtotal indicates total strain, εe indicates elastic strain, ε p indicates plastic strain, εth
indicates thermo-metallurgical strain and εtr indicates phase change strain. For high carbon
steels, the solid–solid transformation has a considerable effect on the mechanical behavior.
The strain caused by the phase transformation mainly considers the effect of the volume
and yield strength changes caused by the austenite–martensite transformation on the
welding residual stress. In addition, the effect of creep-induced strain on the total strain
can be neglected due to the material stays at high temperatures for a very short time
during the whole process. The elastic strain components were modeled using isotropic
Hooke’s law with temperature-dependent Young’s modulus and Poisson’s ratio. The plastic
behavior was modeled using the von Mises criterion, temperature-dependent mechanical
properties and isotropic hardening. The thermo-metallurgical strain is considered the strain
due to the temperature-dependent thermal expansion coefficient and phase change. The
finite element model was set up with experimentally consistent boundary conditions, and
the experimental data were used to validate the weld simulation results. These include
the assumption that the weldolet–branch pipe is free to deform in any direction without
external constraints, but rigid body motion in all directions is prevented. The boundary
conditions of the finite element model are Ux = Uy = Uz = 0 in Figure 4, which are
located at both ends of the weldolet and the branch pipe, respectively. In the welding
experiment, not only the fixture was set, but also the two models were fixed by spot
welding. The position of spot welding is mainly at four symmetrical points, but the heat
input of spot welding is very small, and its influence on welding residual stress can be
ignored. Therefore, the boundary conditions matching the fixture are set in the finite
element simulation process, and the influence of spot welding is not considered.

3.4. Simulation Cases

Figure 7 shows the three welding sequences proposed during the numerical simulation.
Welding sequence path-1 is the continuous welding of two welds in a clockwise circle.
Each layer of weld starts from the 0 position, then proceeds in the clockwise direction,
and finally ends at the 360◦ (0◦ ) position. Welding sequence path-2 is a two-part weld,
with each full-cycle pass divided into two parts. The first part is a two-layer weld path of
0◦ –90◦ –180◦ . The arc of the first layer of welds is clockwise from position 0◦ to position
180◦ , and then the second layer of welds remains clockwise from position 0◦ to 180◦ . The
second part is a 0◦ –270◦ –180◦ weld, with each layer of welds going counterclockwise from
the 0◦ position to the 180◦ . In the welding sequence path-3, each full-circle weld is divided
into four parts. The welding process adopts segmented symmetrical jump welding, and
Materials 2022, 15, 1044

Materials 2022, 15, 1044 9 of 22

the welding direction is clockwise. The arrows in the figure indicate the welding
the welding
tions, direction
and the is clockwise.
numerals Thethe
indicate arrows in the figure
welding steps.indicate the welding directions,
and the numerals indicate the welding steps.

Pass 1
Pass 2

180° 180° 7 180° 6

3 2
Start loca tion:

1 90° 270° 2 2 1 90° 270°3 4 90° 270° End location:

1 4 Start/End location:
0° 0° 5 0° 8

Path-1 Path-2 Path-3

Figure 7. Three welding sequence settings.

Figure 7. finite
The Threeelement
welding sequence
model settings.
in this paper is a multi-layer multi-pass welding, which needs
to control the temperature between layers reasonably. Therefore, three groups of interlayer
The finite
temperatures wereelement
set up for model insimulation,
numerical this paper andisthe
a interlayer
multi-layer multi-pass
temperatures welding,
suitable
for this model were analyzed. The welding case of this numerical simulation
needs to control the temperature between layers reasonably. Therefore, three gro can be
obtained by permutation and combination of the two welding factors, as shown in Table 3.
interlayer temperatures were set up for numerical simulation, and the interlayer te
atures
Table 3.suitable for this cases.
Welding simulation model were analyzed. The welding case of this numerical s
tion can be obtained by permutation and combination of the two welding fact
Case Welding Sequence Preheating Temperature/◦ C Interlayer Temperature/◦ C
shown in Table 3.
Case 1 Path-1 150 150
Case 2 Path-1 200 200
TableCase 3
3. Welding Path-1 cases.
simulation 300 300
Case 4 Path-2 150 150
Case 5 Path-2 200 200
Case
Case 6 Welding Sequence
Path-2 Preheating
300Temperature/°C Interlayer
Tempera
300
Case
Case 1 7 Path-3
Path-1 150 150 150
150
Case 8 Path-3 200 200
Case 29
Case Path-1
Path-3 300 200 200
300
Case 3 Path-1 300 300
4. Case 4 and Discussion
Results Path-2 150 150
4.1.Case 5
Comparison Path-2 Result and Numerical Simulations
of Experimental 200 200
Case 6
Obtaining Path-2temperature field of welded300
a reasonable joints is the prerequisite for the300
analysis
Case 7 of welding residual
Path-3 stress. In order to accurately
150simulate the shape of the weld150
pool and
Case 8 ensure the accuracy
Path-3 of the calculation of the weld
200 residual stress, based on the200
thermal-elastic–plastic finite element model, the heat conduction equations are solved using
Case 9 Path-3 300 300
a multi-threaded parallel technique. Eight threads were called simultaneously during the
temperature field calculation. The calculated transient melt pool shape and the macroscopic
4.shape
Results
of theand Discussion
experimental joint are shown in Figure 8. It can be seen that the temperature
of the fusion zone is above 1520 ◦ C, and the area of the transient heat source’s molten pool
4.1. Comparison of Experimental Result and Numerical Simulations
is almost equal to the area of the weld channel. The calculated results of the weld molten
pool Obtaining a reasonable
are in good agreement with temperature
the experimental field of welded
results, indicatingjoints is the
that the prerequisite
calculated
results of of
analysis thewelding
temperature field arestress.
residual valid and
In reasonable.
order to accurately simulate the shape of th
In order to verify the prediction accuracy
pool and ensure the accuracy of the calculation of the developed calculation
of the weld method,
residual we based
stress,
compared the experimental measurement results of transient temperature and residual
thermal-elastic–plastic
stress with the finite elementfinite element
simulation model,
results. The the heat
k-type conduction
thermocouple equations
is used to mea-are solv
ing
surea the
multi-threaded parallel
transient temperature technique.
at different Eight
positions onthreads
the outerwere called
surface of thesimultaneously
dissimilar
the temperature
steel fieldposition
welded joint. The calculation. The of
distribution calculated transient
the thermocouples melt
on the pool
outer shape
surface of and th
the welded component is shown in Figure 3. They are located 16.5 mm
roscopic shape of the experimental joint are shown in Figure 8. It can be seen th from the centerline
of the weld on the side of the weldolet and 16.5 mm from the centerline of the weld on the
temperature of the fusion zone is above 1520 °C, and the area of the transient heat so
side of the branch. The residual stress is measured by blind hole method and stress measur-
molten pool is almost equal to the area of the weld channel. The calculated results
weld molten pool are in good agreement with the experimental results, indicating t
calculated results of the temperature field are valid and reasonable.
 Materials 2022, 15, 1044 10 of 22

Materials 2022, 15, 1044 10 of 22

ing instrument. The location of the stress measurement points in the welding experiment is
shown in Figure 3.
Figure 8. The shape of the weld pool obtained through experiments and finite element simula-
tions.

In order to verify the prediction accuracy of the developed calculation method, we

compared the experimental measurement results of transient temperature and residual
stress with the finite element simulation results. The k-type thermocouple is used to meas-
ure the transient temperature at different positions on the outer surface of the dissimilar
steel welded joint. The position distribution of the thermocouples on the outer surface of
the welded component is shown in Figure 3. They are located 16.5 mm from the centerline
of the weld on the side of the weldolet and 16.5 mm from the centerline of the weld on the
side of the branch. The residual stress is measured by blind hole method and stress meas-
Figure 8. The shape of the weld pool obtained through experiments and finite element simulations.
uring instrument. The location of the stress measurement points in the welding experi-
Figure 8. The shape of the weld pool obtained through experiments and finite element simula-
ment is shown in Figure 3.
tions. It can be seen from Figure 9 that there is a certain difference between the transient
It can becurve
temperature seen from Figureby9 the
measured thatthermocouple
there is a certainand difference
the numericalbetween the transient
simulation calculation
temperature curve measured by the thermocouple and the numerical simulation calcula-
result. The peak
In order temperature
to verify obtainedaccuracy
the prediction by the experimental
of the developed measurement
calculation is slightly
method, higher
we
tion result. The peak temperature obtained by the experimental measurement is slightly ◦
than the numerical
compared simulation
the experimental calculation results
measurement result, and the maximum
of transient difference
temperature and isresidual
43.5 C.
higher than the numerical simulation calculation result, and the maximum difference is
Whenwith
stress the the
heatfinite
input is small,
element the heating and The cooling phases of the thermal cycle curve
43.5 °C. When the heat input issimulation
small, the results. k-type
heating and cooling thermocouple is used
phases of the thermal to meas-
cycle
are
ure in
thearegood agreement,
transient but as the heat input increases, the actual cooling rate in the
curve in good temperature
agreement, but at as
different
the heatpositions on the the
input increases, outer surface
actual of the
cooling ratedissimilar
in the
welding
steel weldedprocess
joint.is slightly
The positionlarger than the
distribution calculated
of thevalue, value,
thermocouplesbut the overall
on the trend
outer is in good
welding process is slightly larger than the calculated but the overall trend is insurface
good of
agreement.
the welded It is also seen
component is that, although
shown in Figure theThey
3. measured
are two 16.5
located pointsmm located
from on centerline
the both sides
agreement. It is also seen that, although the measured two points located on both sides of
ofof theweld
weld are at sidethe same thedistance from the16.5center of thetheweld, they have thedifferent onpeak
thethe
weld areonatthe the same ofdistance
weldolet
from and
the center mm from
of the weld, centerline
they have of different weld peak the
temperatures,
side of the branch.
temperatures, heating
heating rates
Therates and
residual cooling rates.
stress isrates.
and cooling measuredThis is
This is by caused
blind
caused by the
byhole different
method and
the different thermophysical
stress meas-
thermophys-
property
uring
ical property parameters
instrument. Theof
parameters ofthe
thedifferent
location of the base
different materials.
stressmaterials.
base measurement 15CrMo
15CrMo steel
points
steel in has
has the awelding
a higherhigherthermalthermal
experi-
conductivity
ment is shown
conductivity and
and specific
inspecific
Figure heat heat capacity coefficient, and therefore higher
3. capacity coefficient, and therefore higher peak temperature peak temperature
andheating
and Itheating
can be and
andseen cooling
cooling rates.
fromrates.
Figure From
From this,
this,
9 that thethe
there isverification
verification
a certain results
results show
difference show
that that the
theestablished
the established
between transient
heat source model
heat source model
temperature simulates
curvesimulates
measuredthe the
byheatheat process
the process of the weldolet–branch
of the weldolet–branch
thermocouple and the numerical pipe dissimilar
pipesimulation
dissimilar steel steel
calcula-
welding
welding
tion result.well,
well,
The which
which
peaklays lays the foundation
the foundation
temperature for
for the
obtained the stress
bystress calculation.
calculation. measurement is slightly
the experimental
higher than the numerical simulation calculation result, and the maximum difference is
500 500
43.5 °C. When the heat input is Pipe-16.5mm
0°：Branch small, the FEMheating and cooling phases of the thermal
0°：Weldolet-16.5mm FEM cycle
0°：Branch 0°：Weldolet-16.5mm Exp
curve are in good agreement, but as theExp
Pipe-16.5mm heat input increases, the actual cooling rate in the
400 400
welding process is slightly larger than the calculated value, but the overall trend is in good
350
400
Temperature[℃]
Temperature[℃]

350 300
Temperature(℃)
Temperature(℃)

agreement.
300
It is also seen that, although the measured
300
300
two points located on both sides of 250

250
the weld are at the same distance from the center of the weld, they have different peak
200
200

150

temperatures,
200
heating rates and coolingTime[S]
rates. 200
150
0 This is caused by the different
50 100 150 200 thermophys-
250
Time[S]
300
0 50 100 150 200 250 300

ical property parameters of the different base materials. 15CrMo steel has a higher thermal
conductivity
100
and specific heat capacity coefficient, 100
and therefore higher peak temperature
and heating and cooling rates. From this, the verification results show that the established
heat source
0
model simulates the heat process of0the weldolet–branch pipe dissimilar steel
0 500 1000 1500 0 500 1000 1500 2000 2500 3000
welding well, which lays the2000 2500
foundation 3000
for the stress calculation.
Time(S) Time(S)

500 (a) 500 (b)

0°：Branch Pipe-16.5mm FEM 0°：Weldolet-16.5mm FEM
Figure
Figure9.9.Comparison
Comparisonofofpredicted
predicted andandmeasured
measured
0°：Branch Pipe-16.5mm Exp
values of transient
values temperature:
of transient (a) branch pipeExp
：Weldolet-16.5mm
temperature:
0° (a) branch pipe
side,400
(b) weldolet side. 400
side, (b) weldolet side. 400
350
Temperature[℃]
Temperature[℃]

350 300
Temperature(℃)
Temperature(℃)

300We
measured the residual stresses at selected points on the outer surface of the
300 250
300 250
200

weldolet and branch pipe, respectively, at 90◦ cross-section. The five measuring points are
200
150
150 0 50 100 150 200 250 300

located
200 at the centerline of the weldTime[S] and at 9.5 200
mm and 20 mm from the centerline
0 50 100 150 200
Time[S] of the
250 300

weld on both sides of the weld. The experimental results and finite element simulation
results
100
are shown in Figure 10 with error lines for 100
the experimental data. It can be seen that
the results are reasonably consistent with each other, except for the close matching of trends.
For the existence of the difference, the reason is attributed
0
to three aspects: the first is the
0
existence of errors between the finite element model and the1000
0 500 1000 1500 2000 2500 3000 0 500 actual welded
1500 2000 components.
2500 3000
Time(S) Time(S)
The second is that the position of the experimental measurement point and the mesh node
(a) (b)
Figure 9. Comparison of predicted and measured values of transient temperature: (a) branch pipe
side, (b) weldolet side.
 trends. For the existence of the difference, the reason is attributed to three a
is the existence of errors between the finite element model and the actual w
nents. The second is that the position of the experimental measurement
Materials 2022, 15, 1044 mesh node of the corresponding point in the finite element model 11 of 22 cann

matched, because the volume mesh node in the finite element model is gen
ing to the model size and cannot be changed at will. The third is the numer
of the corresponding point in the finite element model cannot be perfectly matched, because
of volume
the the finite
meshelement
node in themodel set tomodel
finite element the ideal state,according
is generated that is,tobased
the modelonsize
the actua
and cannot
cess, setbetochanged
matchat will.
the The third is the
welding numerical
process simulation of material
parameters, the finite element
thermodyn
model set to the ideal state, that is, based on the actual welding process, set to match
properties parameters, boundary conditions, etc., but to ignore the residua
the welding process parameters, material thermodynamic physical properties parameters,
erated by
boundary the welding
conditions, etc., butparts in the
to ignore the pre-processing processbybefore
residual stresses generated welding re
the welding
parts in thethe
inside pre-processing
welded process
parts.before
Based welding
on residual
the abovestresses inside the welded
analysis, parts. eleme
the finite
Based on the above analysis, the finite element calculation method established in this study
method established in this study can be used to study the temperature and
can be used to study the temperature and residual stress distribution in the multi-layer
distribution
multi-pass injoint
welded theofmulti-layer multi-pass
the weldolet–branch pipe. welded joint of the weldolet–bra

300
Weldolet Branch Pipe
200

100
Stress(MPa)

-100

-200
FEM-Circumferential
Exp-Circumferential
-300 FEM-Longitudinal
Exp-Longitudinal
-400
-40 -30 -20 -10 0 10 20 30 40
Distence from the weld center line(mm)
Figure
Figure Comparison
10. 10. of the residual
Comparison of thestress obtained
residual from obtained
stress the experiment
fromandthe
the finite element
experiment and th
calculation.
calculation.
4.2. Simulation Results of Thermal Field
4.2.The
Simulation Results
thermal field of the of Thermal Field
weldolet–branch pipe structure is shown in Figure 11; the
temperature at the center of the molten pool is much higher than the melting point of
the weld The thermal
metal by 1520 ◦field of the the
C. Obviously, weldolet–branch
shape of the ellipticalpipemeltstructure is shown
pool in the weld is in
temperature
consistent with theatdouble
the center of the
ellipsoidal heatmolten pool is
source model. Themuch higher
distribution than the melti
of isotherms
isweld
characterized by a dense front and a sparser rear. At the same
metal by 1520 °C. Obviously, the shape of the elliptical melt pool in thtime, the temperature
field distribution on both sides of the weld centerline is not symmetrical, the heat affected
sistent
zone on thewith the double
12Cr1MoV ellipsoidal
side is significantly heat source
narrower than that model.
of 15CrMo The
and distribution
the high o
characterized
temperature area ofby a dense
15CrMo front
is also wider. and
Theareason
sparser rear.
is that At theconductivity
the thermal same time,of the tem
15CrMo steel is higher
distribution than that
on both sidesof 12Cr1MoV
of the weld steel,centerline
which makesis thenottemperature diffusionthe hea
symmetrical,
rate and cooling rate faster on the 15CrMo side, resulting in a wider high temperature
on and
area the a12Cr1MoV side iszone
larger heat-affected significantly
on the 15CrMo narrower than
side. In order to that ofanalyze
further 15CrMo the and th
ature areachange
temperature of 15CrMo is also
of dissimilar steel wider. The
joints in the reason
welding is that
process, the the
nodethermal conductiv
on the branch
side of the welded components at the 0 ◦ position cross-section in different welding cases
steel is higher than that of 12Cr1MoV steel, which makes the temperature
is selected from the center of the weld at 10.6 mm to draw the thermal cycle curve. In the
and cooling
weldolet rate
side of the samefaster onfrom
selection thethe15CrMo side,
center of the resulting
weld’s 10.6 mm node,in acomparative
wider high tem
and a of
analysis larger heat-affected
the weldolet side and branchzoneside on ofthe
the15CrMo
same distanceside. In the
from order to further
centerline of an
the weld thermal cycling curve, as shown in Figure 12.
perature change of dissimilar steel joints in the welding process, the node
side of the welded components at the 0° position cross-section in different
is selected from the center of the weld at 10.6 mm to draw the thermal cyc
 weldolet side of the same selection from the center of the weld’s 10.6 mm nod
Materials 2022, 15, 1044 tive analysis of the weldolet side and branch side of the same distance
12 of 22 from t

Materials 2022, 15, 1044 of the weld thermal cycling curve, as shown in Figure 12. 12 of 22

weldolet side of the same selection from the center of the weld’s 10.6 mm node, compara-
tive analysis of the weldolet side and branch side of the same distance from the centerline
of the weld thermal cycling curve, as shown in Figure 12.

(a) (b)
(a) (b)
Figure 11.
Figure Numerically
11.Numerically
Numerically estimated thermal thermal
estimated field: (a) first layer(a)
weld andlayer
its cross section, (b)its
second
Figure 11. estimated thermal field: (a) firstfield:
layer weld first
and weld
its cross section, and
(b) secondcross secti
layer weld and its
its cross
crosssection.
section.
layer weld and its cross section.
layer weld and

500 500
500 Branch Pipe-0°：Case 1 500 Branch Pipe-0°：Case 4
Branch Pipe-0°：Case 2 Branch Pipe-0°：Case 5
Branch Pipe-0°：Case
Branch Pipe-0°：Case 3
1 Branch Pipe-0°：Case 6
Bran
400 400
Branch Pipe-0° ：Case 2 Bran
Branch Pipe-0°：Case 3 Bran
Temperature(℃)

Temperature(℃)

400 400
300 300
Temperature(℃)

Temperature(℃)
200
300 200 300

100 100
200 200
0 0
0 500 1000 1500 2000 0 500 1000 1500 2000
(a) Time(S) (b) Time(S)
100 100
500
Branch Pipe-0°：Case 7 Weldolet-0°：-10.6mm
Branch Pipe-0°：Case 8 400 Branch Pipe-0°：10.6mm
400 Branch Pipe-0°：Case 9
0 0
0 500 1000 1500 2000 0 500 1000
Temperature(℃)

Temperature(℃)

300
(a)
300 Time(S) (b) Time(S)
500
200
Branch Pipe-0°：Case 7 Weldol
200
Branch Pipe-0°：Case 8 400 Branch
400 Branch Pipe-0°：Case 9
100 100
Temperature(℃)

Temperature(℃)

300
0 0
300 0 500 1000 1500 2000 0 500 1000 1500 2000
(c) Time(S) (d) Time(S)

Figure 12. Temperature history curve (a) Case 1–3 (b) Case 4–6 (c) Case200
7–9 (d) Thermal cycle com-
200 12. Temperature history curve (a) Case 1–3 (b) Case 4–6 (c) Case 7–9 (d) Thermal cycle
Figure
parison between the weldolet-side node and the branch-side node.
comparison between the weldolet-side node and the branch-side node.

Figure 12a–c respectively show the temperature distribution 100onon thethe

outer surface of of
100Figure 12a–c respectively show the temperature distribution outer surface
dissimilar steel joints at 0°◦section under nine different welding cases (Case
dissimilar steel joints at 0 section under nine different welding cases (Case 1–Case 9). 1–Case 9). It It
can be observed that all thermal cycling curves have four peaks and troughs,
can be observed that all thermal cycling curves have four peaks and troughs, which is which is due
to the
due 0 fact
to thethat
factthe
that0°the
position is bothisthe
0◦ position weld
both thestart
weldand weld
start end
and 0point
weld in the
end three
point weld-
in the three
ing sequences.
0 Due500 to the difference
1000 in temperature
1500 between
2000 welding
0
welding sequences. Due to the difference in temperature between welding layers, the layers, the
500 peak 1000
peak
(c)
temperature and the trough
temperature and the trough Time(S) temperature are kept within a (d)
specific temperature
temperature are kept within a specific temperature range. Due range. Time(S)

Figure 12. Temperature history curve (a) Case 1–3 (b) Case 4–6 (c) Case 7–9 (d) Therm
parison between the weldolet-side node and the branch-side node.
Materials 2022, 15, 1044 13 of 22

to the different welding sequence, the time node of the peak appearance is also different.
As the heat input increases, the peak temperature also increases. Figure 12d shows the
temperature distribution on the side of the weldolet and the side of the branch pipe. It
can be seen that although the distance from the center of the weld is the same, their peak
temperatures and cooling rates are different. The peak temperature on the branch pipe
side is lower, but the cooling rate is significantly higher than on the weldolet side. This is
consistent with the conclusions obtained above. The characteristics of the thermal cycle
curve change are very consistent with the characteristics of dissimilar steel welding. That
is, the area of the heat-affected zone and the temperature conduction rate on the 15CrMo
side are higher.

4.3. Welding Residual Stress along a Defined Path

The purpose of this study is to investigate the influence of the interlayer temperature
and welding sequence on the residual stress distribution of dissimilar steel joints. In order
to study the difference of residual stress distribution under nine cases, we analyzed the
residual stress of the defined path-4 (shown in Figure 3). Path-4 is the centerline of the
second weld surface.
Figure 13 compares the circumferential residual stress distribution along defined path-
4 under nine welding cases. It can be seen from Figure 13a that the circumferential residual
stress distribution of Case 1–3 (path-1) is very similar, because the welding sequence path-1
is used in these three cases, and the cladding sequence of the weld is the same. Comparing
Case 1–3 carefully, we can find that the main difference between the three welding cases
is the peak of the circumferential residual stress, which reaches a maximum value of
350 MPa at 0◦ (welding start position) in Case 3 (interlayer temperature of 300 ◦ C). The
circumferential residual stresses in Case 1 and Case 2 also reach a maximum around 0◦ ,
but the peak residual stress is slightly smaller than in Case 3. This is mainly due to the
change in interlayer temperature of the weld. At the same time, we can find that for the
welding sequence path-1, the circumferential residual stress at the position from 0◦ to 30◦
has a sudden change, and the circumferential residual stress at the position from 315◦ to
0◦ is significantly higher than other positions. The reason is that the 0◦ position is not
only the starting point of the weld or the end point of the weld; it has experienced four
thermal cycles, and multiple instantaneous heating and cooling instances lead to large
plastic deformation of the metal material, so there is a large internal circumferential residual
stress. Figure 13a also shows that within the range of ±30◦ on the left and right sides of the
weld starting point at 0◦ , the circumferential residual stress on the left is much larger than
that on the right. This is because the left side weld belongs to the post-welded side, while
the right side belongs to the first side. The welding heat generated during the welding of
the later side reduces the circumferential residual stress inside the weld on the first side.
Figure 13b shows the distribution of the circumferential residual stresses along the
defined path for Case 4–6 (path-2). The maximum value of the circumferential residual
stress is 326 MPa, which occurs at 210◦ in Case 4 (interlayer temperature of 150 ◦ C), and
also at the end of the weld on the back side. In addition, the high stress areas in Case 4–6 are
mainly distributed in the 180◦ –240◦ area position and 315◦ –360◦ (0◦ ) area position, which is
mainly due to the fact that these two areas belong to the start and end of the weld position on
the back weld side in path-2. This conclusion is very similar to the circumferential residual
stress distribution characteristics of Cases 1–3, above. In contrast, the circumferential
residual stresses in the symmetrical positions of 0◦ –45◦ and 120◦ –180◦ are the smallest.
By comparing and analyzing Figure 13a,b, we can find that the area distribution of the
high stress area of the single-path straight-through welding method path-1 is relatively
single and exists only within about 45◦ before the end point of welding. While the high
stress area of the two-part welding sequence path-2 is more symmetrical and has a larger
distribution area, there are large circumferential residual stresses at the welding start and
end points of the rear welding side, but this welding sequence (path-2) also reduces the
Materials 2022, 15, 1044 14 of 22
Materials 2022, 15, 1044 14 of 22

start and end points of the rear welding side, but this welding sequence (path-2) also re-
circumferential residual stress on stress
the first ◦ –180◦ area of
duces the circumferential residual onwelding
the firstside, which
welding is atwhich
side, the 105
is at the 105°–
path-2.
180° areaThe circumferential
of path-2. residual stress
The circumferential is significantly
residual lower than lower
stress is significantly path-1.than path-1.

345 0 15 Case 1 345 0 15 Case 4

350 400
330 30 Case 2 350 330 30 Case 5
300
315 45 Case 3 300 315 45 Case 6
250
250
200 300 60 300 60
200
150
150
100 285 75 100 285 75
50 50
0 270 90 0 270 90
50 50
100 255 105 100 255 105
150
150
200
200 240 120 240 120
250
250 300
225 135 225 135
300 350
350 210 150 400
210 150
195 180 165 195 180 165
(a) (b)
345 0 15 Case 7
350 330 30 Case 8
300 315 45 Case 9
250
200 300 60
150
100 285 75
50
0 270 90
50
100 255 105
150
200 240 120
250
300 225 135
350 210 150
195 165
(c) 180

Figure
Figure13.13.Circumferential residual
Circumferential stress
residual distribution
stress along
distribution path-4
along for different
path-4 welding
for different cases.cases.
welding (a)
Case 1–3 (welding sequence path-1) (b) Case 4–6 (welding sequence path-2) (c) Case 7–9 (welding
(a) Case 1–3 (welding sequence path-1) (b) Case 4–6 (welding sequence path-2) (c) Case 7–9 (welding
sequence
sequencepath-3).
path-3).

Figure
Figure13c 13cshows
showsthe thedistribution
distributionofofthe thecircumferential
circumferentialresidualresidualstresses
stressesalong
alongthe the
defined path for Case 7–9 (path-3). From the figure, it can be
defined path for Case 7–9 (path-3). From the figure, it can be found that the maximum found that the maximum
value
valueofofthe theresidual
residualstress
stressisis328
328MPa,
MPa,whichwhichoccurs
occursatatthetheposition
positionofofthe 162.5◦region
the162.5° regionofof
Case
Case7 7(interlayer
(interlayertemperature
temperatureofof150 ◦
150°C). C).We
Wealso
alsofound
foundananinteresting
interestingphenomenon
phenomenonthat that
thecircumferential
the circumferentialresidualresidualstress
stressininthe 0◦ –90◦and
the0°–90° 180◦ –270◦regions
and180°–270° regionsisislowerlowerthanthanthe the
circumferentialresidual
circumferential residualstress
stressininthe 90◦ –180◦and
the90°–180° 270◦ –0regions,
and270°–0° ◦ regions, the reason is that the
the reason is that the
residualstress
residual stressininthe
thefirst
firstsection
sectionofofthetheweld’s
weld’sresidual
residualstress
stressisissignificantly
significantlysmaller
smallerthan than
the second section of the weld. For the welding sequence path-3, the positions of 0 ◦ , 90◦ ,
the second section of the weld. For the welding sequence path-3, the positions of 0°, 90°,
180◦and
180° and270° ◦ are the start and end points of the weld, all of which have experienced four
270are the start and end points of the weld, all of which have experienced four
thermalcycles,
thermal cycles,butbutthe
thecircumferential
circumferentialresidual
residualstresses
stressesatatthe 90◦and
the90° 270◦positions
and270° positionsare are
lowerthanthanthose
thoseatatthe ◦
the0°0and and180° ◦
180positions.
positions.This Thismay
maybebedue duetotothethefact
factthat
thatthetheprevious
previous
lower
weldwill
weld willbebereheated
reheatedwhen whenthe thesubsequent
subsequentprocessprocessisisperformed,
performed,sosothe theresidual
residualstress
stress
caused by the previous welding process will be significantly
caused by the previous welding process will be significantly changed. If the heat input changed. If the heat input
of
the subsequent weld channel is large enough, the stress of the previous weld and its vi-its
of the subsequent weld channel is large enough, the stress of the previous weld and
vicinity
cinity willwill be greatly
be greatly offset
offset because,
because, during
during heating,
heating, thethe
highhigh temperature
temperature can can sufficiently
sufficiently
soften the
soften the area. area.
FromFigure
From Figure13a–c,
13a–c,ititcancanbebefound
foundthatthatthe
theinterlayer
interlayertemperature
temperaturemainly mainlyaffects
affectsthe the
maximum value of the residual stress and the overall magnitude
maximum value of the residual stress and the overall magnitude of the residual stress. of the residual stress.
Whenthe theinterlayer
interlayertemperature
temperatureisis150 150°C ◦ C or 300 ◦ C, the peak value of the residual stress
When or 300 °C, the peak value of the residual stress
isislarger.
larger.TheThewelding
weldingsequence
sequencehas haslittle
littleeffect
effectononthe
themaximum
maximum value
value ofof residual
residual stress.
stress.
The welding sequence mainly affects the distribution of residual
The welding sequence mainly affects the distribution of residual stress and is a decisive stress and is a decisive
factor affecting residual stress. By adjusting the welding sequence, not only can the residual
 Materials 2022, 15, 1044 15 of 22

stress distribution area be changed, but the residual stress in a specific area can also be
reduced. Figure 13 also shows that the weld on the rear weld side largely changes the
residual stresses within and near the first few welds, and the high stress areas are mostly
concentrated at the weld on the rear weld side.
Figure 14a–c compares the axial residual stress distribution along the defined path
under nine simulation cases. Similar to the circumferential residual stress, the effect of
interlayer temperature is small, while the difference in cases for different welding sequences
is obvious. The maximum axial residual stress is 249 Mpa. Figure 14a shows the axial
residual stress distribution of Case 1–3 (path-1); it can be seen that the peak residual stress
still occurs under the welding Case 3. The axial residual stresses near the 0◦ position
(welding start/end point) vary quite significantly, which is very similar to the conclusions
drawn above for the circumferential residual stresses. At the same time, it can be seen that
the area with higher axial residual stress of the welding sequence path-1 is distributed at
the position of 0◦ –45◦ , which is on the right side of the welding starting point of the weld.
The area with higher circumferential residual stress of path-1 is mainly on the left side
of the end point of the weld. The last welded seam mainly affects the distribution of the
Materials 2022, 15, 1044 16 of
high stress area of the circumferential residual stress, while the most initially welded 22
seam
mainly affects the distribution of the high stress area of the axial residual stress.

345 0 15 Case 1 345 0 15 Case 4

250 300
330 30 Case 2 330 30 Case 5
200 315 45 Case 3 250 315 45 Case 6
200
150 300 60 300 60
150
100
100
285 75 285 75
50 50

0 270 90 0 270 90

50 50
255 105 255 105
100
100
150
150 240 120 240 120
200
200 225 135 250
225 135

250
210 150 300
210 150
195 180 165 195 180 165
(a) (b)
345 0 15 Case 7
250
330 30 Case 8
200 315 45 Case 9
150 300 60
100
285 75
50

0 270 90

50
255 105
100

150 240 120

200 225 135

250
210 150
195 180 165
(c)
Figure
Figure14.
14.Axial
Axialresidual
residualstress
stressdistribution
distributionalong
alongpath-4
path-4for
fordifferent
differentwelding
weldingcases.
cases.(a)
(a)Case
Case1–3
1–3
(welding
(weldingsequence
sequencepath-1)
path-1)(b)
(b)Case
Case4–6
4–6(welding
(weldingsequence
sequencepath-2)
path-2)(c)
(c)Case
Case7–9
7–9(welding
(weldingsequence
sequence
path-3).
path-3).

4.4. Effect of Welding

Figure Sequence
14b compares theonaxial
Residual Stressstress distribution of Case 4–6 (path-2) along
residual
the defined
From the above conclusions, it can bethe
path. The maximum value of axial
seen residual
that stress is
the number of266 Mpa, cycles
thermal which experi-
appears
in Case 5. The axial residual stress in the range of 0 ◦ –180◦ experienced a change trend of
enced by the three welding sequences at 0° position is the same, and the distribution of
increasing–decreasing–increasing,
residual stresses is very similar, so and the areas where
the following analysisthefocuses
residualonstress increased were
the distribution of
mainly distributed near the welding start and end positions. However, it
residual stresses at 180°, 90° and 270° sections. Figure 15a–d shows the circumferential is reduced near
and 90◦ area
the axial in the stress
residual middledistributions
of the weld. onThis is inner
the becauseand 0◦outer
and 180 ◦ positions are the welding
surfaces at the 180° section.
It can be seen from the figure that, although path-1 experienced only two thermal cycles
at the 180° position, the overall residual stress distribution trend for path-1 is similar to
that of path-2 and path-3. The residual stresses in the three welding sequences did not
show a significant magnitude relationship. From Figure 15a,b, the circumferential resid-
Materials 2022, 15, 1044 16 of 22

start and end points of the welding sequence path-2, respectively, and the residual stress
near the end of the weld is slightly larger than that near the starting point of welding.
Furthermore, we found that the residual stress distribution at the position of the 180◦ –360◦
region (left side of Figure 14b) has good continuity, but the overall residual stress value is
larger than the right side.
Figure 14c shows the axial residual stress distribution of Case 7–8 (path-3) along
the defined path. It can be seen that the axial residual stress distribution of path-3 is
discontinuous, and there are multiple fluctuations. The maximum value of the residual
stress is 243 Mpa, which appears in Case 1. However, the overall value of the residual stress
in the defined path of path-3 is smaller than that of path-1 and path-2. The start point and
end point of the welding seam of path-3 are at the same position, and they are located at the
positions of 0◦ , 90◦ , 180◦ and 270◦ , respectively. The axial residual stresses near these four
locations are lower, and higher axial residual stresses are distributed at the weld seam in
the weld steady state, which is the opposite trend to the distribution of the circumferential
residual stresses in path-3.
From the Figures 13 and 14, we can know that the value of the circumferential residual
stress along the defined path is usually lager than the value of the axial residual stress.
Setting a reasonable range of interlayer temperature can effectively reduce the peak value of
the residual stress of the weld. The welding sequence directly determines the distribution
of the welding residual stress, and there will always be large fluctuations in the residual
stress near the welding start/end point. The above mainly analyzes the residual stress
distribution at the weld, and the following will further analyze the residual stress on
both sides of the weld. In addition, the maximum values of the circumferential and axial
residual stresses occur in the welding cases with interlayer temperatures of 150 ◦ C or 300 ◦ C.
Therefore, we choose the welding cases with interlayer temperatures of 200 ◦ C and analyze
the residual stresses on the weldolet side and the branch side at different cross-sections.

4.4. Effect of Welding Sequence on Residual Stress

From the above conclusions, it can be seen that the number of thermal cycles experi-
enced by the three welding sequences at 0◦ position is the same, and the distribution of
residual stresses is very similar, so the following analysis focuses on the distribution of
residual stresses at 180◦ , 90◦ and 270◦ sections. Figure 15a–d shows the circumferential
and axial residual stress distributions on the inner and outer surfaces at the 180◦ section.
It can be seen from the figure that, although path-1 experienced only two thermal cycles
at the 180◦ position, the overall residual stress distribution trend for path-1 is similar to
that of path-2 and path-3. The residual stresses in the three welding sequences did not
show a significant magnitude relationship. From Figure 15a,b, the circumferential residual
stress on the outer surface has experienced tensile stress-compressive stress-tensile stress
from the center of the weld to both sides of the weldolet and branch pipe, while the ax-
ial residual stresses on the outer surface experienced compressive-tensile stresses. The
residual stress distribution on both sides of the weld is not symmetrical. There is a very
large stress gradient at the fusion line on both sides of the weld, and the peak value of
the axial residual stress reaches 310 Mpa on the 12Cr1MoV steel side. This is due to the
large differences in the thermophysical properties of dissimilar materials, and it is also
a very obvious feature of dissimilar steel welding. The thermal expansion coefficients
of 12Cr1MoV steel and 15CrMo steel are different, and the expansion and contraction of
the two materials are different during the welding heating and cooling processes, which
ultimately causes the residual stress gradient on both sides of the weld to be larger and the
distribution asymmetrical.
Figure 15c,d shows the circumferential and axial residual stress distributions on the
inner surface at the 180◦ section. The circumferential residual stress on the inner surface
has a similar distribution trend to that on the outer surface, while the axial residual stress
on the inner surface has an opposite direction to that on the outer surface. It can also be
found that the circumferential and axial residual stress values at the inner surface of the
Materials 2022, 15, 1044 17 of 22

weld are significantly higher than the outer surface, the circumferential residual stress
peak on the inner surface is about 425 Mpa, and the axial residual stress peak is about
370 Mpa. This shows that the residual stress of the 12Cr1MoV/15CrMo dissimilar steel
welded joint is more obvious in the bottom weld. At the 180◦ section, the adjustment of
Materials 2022, 15, 1044 17 of 22
the welding sequence caused the change in the peak value and distribution trend of the
welding residual stress, but it is impossible to judge which welding sequence is better.

（a） （b）
200 Case2:Path-1 12Cr1MoV 15CrMo
Case5:Path-2 100
150 Case8:Path-3

100 0
Stress(MPa)

Stress(MPa)
50
-100
0

-50 -200

-100 Case2:Path-1
-300 Case5:Path-2
-150 12Cr1MoV 15CrMo Case8:Path-3

-40 -30 -20 -10 0 10 20 30 40 -40 -30 -20 -10 0 10 20 30 40

（c） Distance from the weld center line(mm) （d） Distance from the weld center line(mm)
500
Case2:Path-1 Case2:Path-1
400
400 Case5:Path-2 Case5:Path-2
Case8:Path-3 Case8:Path-3
300 300
Stress(MPa)

Stress(MPa)

200
200

100
100
0

0
-100
12Cr1MoV 15CrMo 12Cr1MoV 15CrMo
-200 -100
-40 -30 -20 -10 0 10 20 30 40 -40 -30 -20 -10 0 10 20 30 40
Distance from the weld center line(mm) Distance from the weld center line(mm)

Figure 15.
Figure 15. Circumferential
Circumferentialand
andaxial residual
axial stress
residual distribution
stress of Case
distribution of 2, Case
Case 2,5Case
and Case
5 and8 at 180°8 at
Case
section.
◦ (a) Circumferential residual stress on the outer surface. (b) Axial residual stress on the outer
180 section. (a) Circumferential residual stress on the outer surface. (b) Axial residual stress on the
surface. (c) Circumferential residual stress on the inner surface. (d) Axial residual stress on the inner
outer surface. (c) Circumferential residual stress on the inner surface. (d) Axial residual stress on the
surface.
inner surface.
Figure 15c,d shows the circumferential and axial residual stress distributions on the
Figure 16a–d shows the circumferential and axial residual stress distributions on the
inner surface at the 180° section. The circumferential residual stress on the inner surface
inner and outer surfaces at the 90◦ section. From Figure 16a,b, it can be found that the
has a similar distribution trend to that on the outer surface, while the axial residual stress
circumferential residual stress distribution trend of the outer surface at the 90◦ section and
on the inner surface has an opposite direction to that on the outer surface. It can also be
the 180◦ section is very similar, but the axial residual stress on the outer surface is quite
found that the circumferential and axial residual stress values at the inner surface of the
different. At the 90◦ section, the distribution of residual stress reflects a certain regularity
weld are significantly higher than the outer surface, the circumferential residual stress
with the change in welding sequence. The circumferential residual stresses at the outer
peak on the inner surface is about 425 Mpa, and the axial residual stress peak is about 370
surface
Mpa. Thiswelds
shows of that
the three welding
the residual sequences
stress are relatively close,
of the 12Cr1MoV/15CrMo but thesteel
dissimilar residual
weldedstress
distributions on the weldolet side and the branch pipe side show obvious
joint is more obvious in the bottom weld. At the 180° section, the adjustment of the weld- differences.
Among them,caused
ing sequence the overall distribution
the change in theof the value
peak circumferential residual
and distribution stress
trend ofon
thethe weldolet
welding
side and the branch pipe side of path-3 is smaller than that of
residual stress, but it is impossible to judge which welding sequence is better.path-1 and path-2. It can
also be seen that there is no significant difference in the axial residual stress
Figure 16a–d shows the circumferential and axial residual stress distributions on the on the outer
surface of path-1 at 90 ◦ and 180◦ , but the direction of the axial residual stress on the outer
inner and outer surfaces at the 90° section. From Figure 16a,b, it can be found that the
surface of path-2residual
and path-3 ◦
circumferential stresshas changed.trend
distribution At theof90
the section, the axial
outer surface at theresidual stresses
90° section and on
the
the weldolet sideisand
180° section verythe branch
similar, butpipe
theside
axialofresidual
path-2 all show
stress on tensile
the outerstress characteristics,
surface is quite
and path-3Atalso
different. themainly shows
90° section, thetensile stress characteristics.
distribution of residual stressThe axialaresidual
reflects stress on the
certain regularity
outer surface has an obvious magnitude relationship. The magnitude
with the change in welding sequence. The circumferential residual stresses at the outer of the axial residual
stress on the weldolet side and the branch side is: path-3 < path-1 <
surface welds of the three welding sequences are relatively close, but the residual stress path-2. This may
be because path-3 has experienced more thermal cycles at the 90 ◦ position. The multiple
distributions on the weldolet side and the branch pipe side show obvious differences.
Among them, the overall distribution of the circumferential residual stress on the weldolet
side and the branch pipe side of path-3 is smaller than that of path-1 and path-2. It can
also be seen that there is no significant difference in the axial residual stress on the outer
surface of path-1 at 90° and 180°, but the direction of the axial residual stress on the outer
 Materials 2022, 15, 1044 18 of 22

the weldolet side and the branch pipe side of path-2 all show tensile stress characteristics,
and path-3 also mainly shows tensile stress characteristics. The axial residual stress on the
Materials 2022, 15, 1044 18 of 22
outer surface has an obvious magnitude relationship. The magnitude of the axial residual
stress on the weldolet side and the branch side is: path-3 < path-1 < path-2. This may be
because path-3 has experienced more thermal cycles at the 90° position. The multiple heat-
ing process
heating is equivalent
process to the
is equivalent tempering
to the process,
tempering which
process, helps
which to reduce
helps the the
to reduce residual
residual
stress inside
stress inside the weld.
weld.

（a） （b）
250 Case2:Path-1 Case2:Path-1
Case5:Path-2 200 Case5:Path-2
200 Case8:Path-3 Case8:Path-3

150 100

Stress(MPa)
Stress(MPa)

100
0
50

0 -100

-50
-200
-100 12Cr1MoV 15CrMo 12Cr1MoV 15CrMo
-40 -20 0 20 40 -40 -20 0 20 40
（c） Distance from the weld center line(mm) （d） Distance from the weld center line(mm)
400 300
Case2:Path-1 Case2:Path-1 15CrMo
Case5:Path-2 Case5:Path-2
300 Case8:Path-3 200 Case8:Path-3

200
Stress(MPa)

Stress(MPa)
100
100
0
0

-100
-100

12Cr1MoV 15CrMo 12Cr1MoV

-200 -200
-40 -20 0 20 40 -40 -20 0 20 40
Distance from the weld center line(mm) Distance from the weld center line(mm)

Figure 16.
Figure 16. Circumferential
Circumferentialand axial
and residual
axial stress
residual distribution
stress of Case
distribution 2, Case
of Case 2,5Case
and Case
5 and 8 at 90° 8 at
Case
section.
◦ (a) Circumferential residual stress on the outer surface. (b) Axial residual stress on the outer
90 section. (a) Circumferential residual stress on the outer surface. (b) Axial residual stress on the
surface. (c) Circumferential residual stress on the inner surface. (d) Axial residual stress on the inner
outer surface. (c) Circumferential residual stress on the inner surface. (d) Axial residual stress on the
surface.
inner surface.
Figure 16c,d shows the distribution of the circumferential and axial residual stresses
Figure 16c,d shows the distribution of the circumferential and axial residual stresses
on the inner surface. It can be seen that the residual stress values near the weld on the
on the inner surface. It can be seen that the residual stress values near the weld on the inner
inner surface are higher than those on the outer surface, which is consistent with the dis-
surface are higher than those on the outer surface, which is consistent with the distribution
tribution of residual stress in the 180° section. Compared with the 180° section, the most
of residual stress in the 180◦ section. Compared with the 180◦ section, the most obvious
obvious change in the internal surface residual stress at the 90° section is still path-3. The
◦ section
change in the internal surface residual stress at the 90
overall distribution of the circumferential residual stress on the inner is still path-3.
surface The overall
of path-3 is
distribution of the circumferential residual stress on the inner surface
smaller than the other two welding sequences, and the peak residual stress at the weld of path-3 is smaller
is
than the other
also smaller, two
only 146welding
MPa. The sequences, andstresses
axial residual the peak onresidual
the innerstress
surface atare
theallweld is also
charac-
smaller, only 146 MPa. The axial residual stresses on the inner surface are
terized by compressive stresses in the 90° section, which is exactly the opposite of the 180° all characterized
by compressive
section. stresses
It can also be found 90◦ section,
in thefrom the figurewhich
that is
theexactly the opposite
axial residual of the
stresses
◦ section.
180inner
at the
Itsurface
can also
weldsbe of
found from
path-3 the figure
are smaller thanthat theofaxial
those path-1 residual stresses
and path-2, at the
but they areinner
largersurface
on
welds of path-3 are smaller than those of path-1 and path-2, but
the weldolet side and the branch side than path-1 and path-2, and the axial residual they are larger on the
weldolet
stresses on side
theand the side
branch branchare side than path-1
somewhat and path-2,
larger than those onand the the
seataxial
side.residual
The 180°stresses
po-
on the branch side are somewhat larger than those on the seat side.
sition is the arc ending point of path-2, which is also the arc starting point/ending The 180◦point
position
of is
the arc ending
path-3. pointand
Both path-2 of path-2, which
path-3 have is also thefour
experienced arc starting
thermal point/ending
cycles at 180°, but point
theof path-3.
axial
Both path-2 and path-3 have experienced four thermal cycles at 180◦ , but the axial residual
stress distribution pattern of the inner and outer surfaces of path-2 at 180◦ is completely
different from that of path-3. This indicates that the number of thermal cycles is not a single
factor affecting the distribution of residual stresses; the location of the weld start/end point
distribution can also affect the distribution of residual stresses.
Figure 17a–d shows the residual stress distribution on the inner and outer surfaces
at the 270◦ section. The 270◦ position is the symmetry point of the 90◦ position, and the
overall trend of the circumferential residual stress distribution on the inner and outer
 residual stress distribution pattern of the inner and outer surfaces of path-2 at 180° is com-
pletely different from that of path-3. This indicates that the number of thermal cycles is
not a single factor affecting the distribution of residual stresses; the location of the weld
Materials 2022, 15, 1044 start/end point distribution can also affect the distribution of residual stresses. 19 of 22
Figure 17a–d shows the residual stress distribution on the inner and outer surfaces
at the 270° section. The 270° position is the symmetry point of the 90° position, and the
overall trend of the circumferential residual stress distribution on the inner and outer sur-
surfaces of these two sections is similar, but the axial residual stress on the inner and outer
faces of these two sections is similar, but the axial residual stress on the inner and outer
surfaces
surfacesis isdifferent.
different.The
The axial
axial residual stresses on
residual stresses onthe
theouter
outersurfaces
surfacesofofpath-1
path-1 and
and path-2
path-2
atatthe 90 ◦ section are mainly tensile stresses, while at the 270◦ section they are mainly
the 90° section are mainly tensile stresses, while at the 270° section they are mainly
compressive
compressive stresses,
stresses,and
and the
the peak
peak ofof compressive
compressivestresses
stressesarearemuch
muchhigher
higherthan than those
those at at
the 90 ◦ section. This may be because the 270◦ position belongs to the rear weld side of
the 90° section. This may be because the 270° position belongs to the rear weld side of
path-1
path-1andandpath-2,
path-2, and
and the
the residual stresses on
residual stresses onthe
therear
rearweld
weldside
sidetend
tendtotobebelarger.
larger.
TheThe
axial ◦ ◦
axialresidual
residualstress
stressdistribution
distribution in in the 90 and
the 90° and 270°
270 sections
sectionsofofpath-3
path-3isissimilar
similar because
because
path-3
path-3isisaasegmented
segmented jumpjump welding
welding method.
method. The Thefirst
firstwelding
weldingareaareaisisthe 0◦ –90and
the0°–90° ◦ and

180 ◦ ◦
–270 area ◦
180°–270° areaposition.
position.ByBycomparing
comparingthe theresidual
residualstress
stressdistribution
distributionat atthe
the270
270°section
section of
the three welding sequences, we can find that the overall distribution
of the three welding sequences, we can find that the overall distribution of circumferentialof circumferential
and
andaxial
axialresidual
residualstresses
stresseson onthe
theouter
outer surface
surface ofof path-3
path-3 is smaller than
is smaller than path-1
path-1and andpath-
path-2,
and the inner surface has the same pattern of circumferential residual stresses.
2, and the inner surface has the same pattern of circumferential residual stresses. The axial The axial
residual stress at the weld on the inner surface of path-3 is much smaller
residual stress at the weld on the inner surface of path-3 is much smaller than path-1 and than path-1 and
path-2,
path-2,butbutthetheaxial
axialresidual
residual stress on the the weldolet
weldoletand andbranch
branchpipe
pipeisislarger
larger than
than path-1
path-1
and
andpath-2,
path-2,and andeventually
eventually tends
tends to 0 MPa.

（a） （b）
100
Case2:Path-1 15CrMo
200 Case5:Path-2
Case8:Path-3 0

100
-100
Stress(MPa)

Stress(MPa)
0 -200

-300
-100

-400 Case2:Path-1
-200 Case5:Path-2
12Cr1MoV 15CrMo 12Cr1MoV Case8:Path-3
-500
-40 -20 0 20 40 -40 -20 0 20 40

（c） Distance from the weld center line(mm) （d） Distance from the weld center line(mm)

400 Case2:Path-1 Case2:Path-1 15CrMo

300
Case5:Path-2 Case5:Path-2
Case8:Path-3 Case8:Path-3
300
200

200
Stress(MPa)

Stress(MPa)

100
100
0
0

-100
-100

12Cr1MoV 15CrMo 12Cr1MoV

-200 -200
-40 -20 0 20 40 -40 -20 0 20 40
Distance from the weld center line(mm) Distance from the weld center line(mm)

Figure17.
Figure 17. Circumferential
Circumferential and
andaxial
axialresidual stress
residual distribution
stress of Case
distribution 2, Case
of Case 5 and 5Case
2, Case and8Case
at 270°
8 at
section. (a) Circumferential residual stress on the outer surface. (b) Axial residual stress on the outer
270◦ section. (a) Circumferential residual stress on the outer surface. (b) Axial residual stress on the
surface. (c) Circumferential residual stress on the inner surface. (d) Axial residual stress on the inner
outer surface. (c) Circumferential residual stress on the inner surface. (d) Axial residual stress on the
surface.
inner surface.

5. Conclusions
In this study, through numerical simulation and experimental verification, the effect
of different interlayer temperatures and welding sequences on the temperature field and
stress field of 12Cr1MoV/15CrMo dissimilar metal arc welding joints were studied. The
conclusions are summarized as follows:
(1) In this study, the Case 2 (interlayer temperature of 300 ◦ C, welding sequence path-
1) model was selected to verify the residual stress and transient temperature. The
Materials 2022, 15, 1044 20 of 22

simulation results are in good agreement with the experimental results, which verifies
the reliability of the experimental model.
(2) The transient temperature distribution results show that the differences in the ther-
mophysical properties of the materials during welding of dissimilar steels lead to
an asymmetric distribution of the transient temperature field about the center of the
weld. The high temperature range of the 15CrMo steel side is larger than that of the
12Cr1MoV steel side, and the heat-affected zone is relatively wider.
(3) The circumferential and axial residual stress distribution on both sides of the weldolet–
branch pipe is not symmetrical, and there are always large fluctuations and stress
gradients in the weld and the area near the weld. There is always a peak residual
stress at the weld fusion line on both sides of the weld.
(4) The interlayer temperature of the weld has little effect on the distribution pattern of
the residual stresses, which mainly affect the peak residual stresses. The peak residual
stress along the defined path occurs more often at interlayer temperatures of 150 ◦ C
or 300 ◦ C.
(5) The welding sequence is a decisive factor affecting the residual stress. By adjusting
the welding sequence, not only can the residual stress distribution area be changed,
but also the residual stress in specific areas can be reduced. The post-welded seam
largely changes the residual stresses near the first weld, and the high stress areas are
mostly concentrated at the post-weld.
(6) The number and position distribution of the start/end point of the weld also effect the
distribution of residual stress, and the distribution trend of circumferential residual
stress and axial residual stress on the outer surface is opposite. The overall residual
stress distribution at the 90◦ section is smaller than the other three sections.
(7) At the 0◦ and 180◦ sections, the residual stress distribution of path-1, path-2 and
path-3 are very similar, and the circumferential and axial residual stresses on the inner
surface are larger than those on the outer surface. However, the residual stresses
on the inner and outer surfaces of the segmental jump welding method path-3 are
smaller than those of path-1 and path-2 in the 90◦ and 270◦ sections as a whole. The
residual stresses reach a minimum in the 90◦ section. It can be concluded that path-3
is more suitable for the welding of weldolet–branch pipe dissimilar steel joints.

Author Contributions: Conceptualization, C.M. and X.H.; methodology, C.M.; software, C.M.;
validation, C.M. and X.Z.; formal analysis, C.M.; investigation, C.M.; resources, X.H. and L.Z.; data
curation, C.M.; writing—original draft preparation, C.M.; writing—review and editing, X.H. and
L.Z.; visualization, C.M.; supervision, X.H. and L.Z.; project administration, B.S. and L.Z.; funding
acquisition, B.S. and L.Z. All authors have read and agreed to the published version of the manuscript.
Funding: This research was funded by the National Natural Science Foundation of China, grant
number 52065055.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: The data presented in this study are available upon request from the
corresponding author. The data are not publicly available due to the requirements of related projects.
Conflicts of Interest: The authors declare no conflict of interest.

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